Self-Study Programme 383 Audi TT coupé 07 body.pdf

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Service Training
Audi TT Coupé ´07 - Body
Self-Study Programme 383
Audi-Space-Frame ASF® of the Audi TT Coupé
The development targets for the bodyshell of the Audi TT
With a weight advantage of 48 % over a comparable all-steel bodyshell, in addition to an optimised weight
distribution, the new composite aluminium-steel spaceframe body of the Audi TT marks yet another mile-
stone in the development of modern Audi bodyshells.
Crash safety of the bodyshell is enhanced by means of load-bearing structures at the front end, sides and rear
end, with a heavy emphasis on pedestrian safety.
To ensure efficient volume bodyshell production, various new joining and production techniques are
employed.
The repair concept is based heavily on the well-known aluminium repair concept. However, of course, the
materials combination of aluminium and steel necessitated that new approaches be taken.
383_001
Contents
Audi Space Frame of the Audi TT
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technological concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combination of steel and aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Comparison of ASF concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Joining techniques and production processes
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Punch riveting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resistance spot welding and MAG welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Structural bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
New joining technique: solid punch riveting (Kerb-Konus riveting) . . . . . . . . . . 16
New joining technique: Flow Drill screwing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
New joining technique: aluminium laser welding . . . . . . . . . . . . . . . . . . . . . . . . . 18
Repair concept
Aluminium repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Aluminium-steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Qualification of aluminium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bodyshell safety concept
Head-on collision, side impact and rear collision . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pedestrian safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electromechanical rear spoiler
The self-study programme teaches the design and function of new vehicle models,
new automotive parts or new technologies.
The self-study programme is not a repair manual!
All values given are intended as a guideline only and refer to the software version valid at the time of
preparation of the SSP.
For maintenance and repair work, always refer to the current technical literature.
Reference
Note
Audi Space Frame of the Audi TT
Dimensions
383_002
Audi TT Coupé ’ 07
Transmission
Kerb weight without driver in kg
Max. perm. gross weight in kg
cw (rear spoiler extended)
Boot capacity in l
Max. power output in kW
vmax in kph
Acceleration 0-100 kph in s
Fuel consumption in l/100 km
* with the rear-seat back folded forward
6.6
7.7
2,0
Manual gearbox
1260
1660
0.3
290 (700*)
147 (200 bhp)
240
6.4
7.7
5.9
10.3
S tronic
1280
1680
3,2 quattro
Manual gearbox
1410
1810
0.3
290 (700*)
184 (250 bhp)
250
5.7
9.4
S tronic
1430
1830
0.31
4
Technological concept
Sheet-steel parts are used for the first time in the
ASF of the new Audi TT in addition to aluminium
castings, aluminium extruded sections and alumin-
ium sheet-metal parts. Collectively, they make up
the body structure. Vehicle weight distribution has
been optimised by using sheet-steel parts in the
rear body section. This has a direct bearing on
sporting characteristics, such as driving dynamics
and acceleration as well as safety characteristics,
such as stopping distance and driving stability
In spite of the partial use of sheet-steel parts, the
total body weight of 277 kg, including attachments
such as doors and lids, is considerably less than
that of a comparable all-steel body.
Although the new TT has grown in size, the gross
weight of the vehicle has been reduced through the
use of the aluminium-steel bodyshell.
The body structure of the new Audi TT has higher
strength and 50 % higher torsional rigidity than its
predecessor.
Aluminium extruded sections
Sheet-aluminium parts
Aluminium castings
Sheet-steel parts
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